I had very similar issues and it turns out that activating Borons using the app is no longer the recommended approach. Please take a look at this thread:
I now use this process:
- I use the "device restore" tool to update to the desired deviceOS version and check the box that turns off the setup bit.
- Put the device in listening mode and open up the command line tools in a terminal. Use the "particle identify" command (device in listening mode) to get the deviceID.
- Then, I add the device to the product I want to on-board it to using "particle product device add". The device comes on, connects and gets the product's firmware all in one go. Much quicker and easier than using the mobile app.
- Finally, I claim the device using the command line tools with "particle device add" and the deviceID.
I know the documentation will be updated and there may be a more efficient process but, this works and can go quite quickly.
Hope this helps,
Chip